Stofacotg material and process of makibtg same



W. F. McKAY. SURFACENG MATERIAL AND PROCESS OF MAKING SAME.

APPLICATION FILED AUG.28. I9I7.

Patented Oct. 7

F. MGKAY, OF LA GRANGE, ILLmOIS.

SURFACING- MATERIAL AND PROCESS OF BIAKING- SAME.

Application filed August 28, 1917.

To all whom it may concern Be it known that 1, WILLIAM F. MGKAY, a citizen of the United States, and a resident of the city of La Grange, in the county of Cook and State of Illinois, have invented certain new and useful Improvements in Surfacing Material and Processes of Making Same; and I do hereby declare that the following is a full, clear, and exact description of the same, reference being had to the accompanying drawings, and to the numerals of reference marked thereon, which form a part of this specification.

This invention relates to an improved process of manufacturing a surfacing material which is well adapted .for use on floors, Walls, ceilings and for other purposes, and according to the use thereof, slight changes in the process well within the scope of this invention may be made to better adapt the material for the particular use to which the material is to be subjected. The process for formation of the surfacingv material is continuous, and takes place through a machine constructed for the purpose, whereby the manufacture of the surfacing material is simplified and made exceedingly economical from a cost consideration.

Heretofore, it has been almost general practice in the manufacture of surfacing material, such as for wall and floor coverings, and roofings to use various kinds of paper, felts and fabric as a base which have in their manufacture consisted of fibrous material reduced to a pulp. It is well known that fibrous materials, such as straw, in their natural state, have great water resistingproperties as well as a natural ability to resist action of the elements where exposed to weather. However, such materials when reduced to a pulp and made into paper, for instance, that known as straw board, lose their resistive properties. ll contemplate the use of artificial or natural fibrous materials retained substantially in their initial or natural statein the formation of a product by a process followed according to the principles of my invention, thus producing at low cost a material having high weather resistive properties, as well as strong wearing qualities.

"It is an object therefore of this invention to provide aprocess for the manufacture of a weatherproof and insulating material adapted for any purpose whatsoever Specification of Letters Patent.

Patented (Diet. ".7, 1919),

Serial No. 188,581.

where the use requires a material of such character, wherein a fibrous material and moisture resisting adhesive material are worked into a homogeneous mass upon a suitable base member, which, upon processing, forms substantially a continuous unitary water-proof fabric, which may be out and shaped to lengths desired and formed with any ornamentation.

It is also an object of this invention to provide a process for the manufacture of a surfacing material wherein a fieXible sheeting is used as a base which is treated on its surface with a binding liquid upon which a fibrous material is afterward placed and worked thereinto with subsequent treatments of' the adhesive material and fibrous material taking place, utilizing, if desired, difi'erent grades of fibrous material'and different grades of adhesive material in the diflferent steps of the process according to the purpose for which the material is to be used, and finally treating the material with a surfacing substanceafter which the material is passed through finishing rolls which may, if desired, impress an ornamentation in the material.

It is furthermore an important object of this invention to provide a material manufactured by a process involving the temporary or permanent use of a base with applications thereto of a binding or adhesive fluid and'layers of fibrous material, and at the same time working the binding fluid and the fibrous material through suitable mechanisms for the purpose to form in substantially a unitary homogeneous fabric and finally giving the same a surface treatment with talc, graphite, gravel, sand, paper, or other material according to the purpose for which the material is to be used.

lt'is a further important object of this invention to provide a process for the manufacture of a wear and weather resisting material, utilizing a fibrous material and adhesive'weather-proof fluid substantially in their natural state reduced to substantially a homogeneous mass and subsequently treated with a surfacing substance, and with the material formed in sheets or lengths of any desired dimension and impressed, if desired, with any ornamentation.

Other and further important objects of the invention will be apparent from the disclosure in the drawings and specification.

ing the process of manufacture of a material according to the principles of my invention.

Fig. 2 is a fragmentary plan View of a sheet of the material with the difierent layers thereof broken away to show the successive steps in the process.

Fig. 3 is a detail section taken on line 33 of Fig. 2.

Fig. 4: is an enlarged detail section taken longitudinally at the left hand end of Fig. 2.

Fig. 5 is an enlarged detail section on line 55 of Fig. 2.

Fig. 6 is an enlarged plan View of the material after the second step in the progress.

As shown on. the drawings:

The material or composition of matter formed according to the principles of my invention, is manufactured in the following manner: Referring to Fig. 1, a reel of paper or other suitable flexible or pliable base member which is desired to be used, denoted by the reference numeral 1, is jour'naled in any suitable means at one end of the machine and the sheet drawn from the reel is led over a roller 2, and downwardly beneath an idler roller 3, disposed within a tank 4. At the point of which the sheeting 1, is led upwardly out of the tank at, a spray pipe 5, is provided, which streams a thin layer of the hinder or adhesive liquid upon the surface of the sheeting, as denoted by the reference numeral 6, shown in Fig. 2. The treated sheeting is then led upwardly through a hopper 7, within which a quantity of straw 8, or other suitable fibrous material, is disposed, which as the sheeting moves along the bottom of the hopper adheres thereto and the sheeting is then led around rolls 9 and 10, respectively, which serve to work the fibrous material well into the binder.

As the material" is passed around the up per roll, any of the straw or other fibrous material which has not been worked into the material but has left the hopper 7, falls back into the hopper, and the material on the sheet then continues around the three roll 11, 12 and 13, where working of the fibrous material into the binder is furthered. The sheeting thus far treated, as it leaves the roller 13, is denoted by the reference numeral 14, as shown in Fig. 2 and passes be neath a tank 15, which streams a further quantity of binder liquid thereon and this point in the process is denoted by the reference numeral 16, in Fig. 2. As the sheeting leaves the tank 15, it passesbeneath a discharging hopper 17, which drops a further nerepec quantity of fibrous material thereon, and this step in the process is denoted by the reference numeral 18, in Fig. 2. The material thus far treated, i then led around and between the rolls 19, 20 and 21, respecstep in the process of formation of the material is denoted by the reference numeral 24, in Fig. 2. The material then leads beneath the discharging hopper 25, which permits a further quantity of the fibrous substance to fall upon the material thus far formed, and this step in the process is denoted by the reference numeral26, after which the material is led around and between rolls 2?, 28 and 29, to thoroughly interwork the binder liquid and the fibrous substances int-o substantially a homogenous mass, this step in the process being denoted by the reference numeral 30.

The material then passes beneath the discharging hopper or tank 31,which sprays a layer of the liquid thereon of a slightly different character from the liquid heretofore used to afford a finishing surface coat upon the material, andthis step is denoted by the reference numeral 32, in Fig. 2. After this step in the process, the material is led beneath the discharging hopper 37,. which sprays a suitable surface substance of graphite, ground cork, talc, sand, gravel, or any other suitable material upon the surface of the product thus far formed, and this step in the process is "denoted by the reference numeral 38. The product thus far formed is then passed around and between the respective rolls 39, 40 and 41, so that any superfluous quantity of the surfacing material which is not worked into the roduct by said rolls, falls therefrom, and t e product at this step in the process is denoted by the reference numeral 42, in Fig. 2. The material is then passed between forming rolls 43 and 44, if so desired, to form an ornamental design thereon and to thoroughly and finally compress the product and this step in the process is denoted by the reference numeral 45. The base is used rimarily as a carrier for the fibrous composition to be formed and may be of a character which permits removal thereof from the finished product if so desired. The product formed is actually a fibrous fabric and is possessed-of exceptionally strong wearing and weather-proof qualities and may be used for many purposes, such as surfacing floors, walls, roofs,

ceilings and the like, or as. an insulation member between walls, floors and ceilings.

ice

liltl struction maybe varied through a wide range without departing from the'prinoiples of this invention, and I therefore do not purpose limiting the patent granted otherwise than necessitated by the prior art.

I claim as my invention:

'1. The process of forming a wear and I weather-proof material consisting in alter nately applying a binder liquid and a layer of straw to the surface of a stance.

2. The process of forming a weather-proof material, consisting in alternately treating ,a base member with layers of binder liqui and straw, and thoroughly interworking the, same to form a unitary and substantially homogeneous product.

,3. The process of forming a wear and Weather-proof material, consisting in the application of a binder fluid to the surface of a sheet and subsequent additions of fibrous material thereto and looping same sheet of sub-' over and under rolls to form a solid pliable sheet o f material. 7

4. The process of forming a wear and weather-proof material by working straw in, its natural state into a binder fluid upon. the surface of a sheet of fibrous. substance.

scribed my name in the 5. A weather-proof sheet composed of straw and adhesive bonding material rolled into a thin, compact mass.

6. A weather proof sheet consisting of a ribbon, a surfacing material, and a layer of criss-cross overlapping strands of fibrous -material bonded together and compressed between and bonded to the ribbon material and the surfacing material to afi'ord tensile strength and impenetra-bility to the: sheet.

7. A weather-proof sheet consisting of a layer of fibrous material comprising overlapping strands, flattened and arranged criss-crossand substantially parallel with the surface of the sheet, and an adhesive material mingled with the strands of fibrous material for combining said strands in a unitary mass.

8. A weather-proof sheet consisting of a ribbon, a layer .of crisscross overlappin strands of fibrous material bonded'to the ribbon, a surfacing material bonded to and covering the layer of iibrous material, said sheet being provided with an ornamental design impressed in the surfacing material and fibrous material. I

In testimony whereof I have hereunto sub- .presence of two subscribing witnesses.

- WILLIAM F. MoKAY. Witnesses:

CHARLES W. HILLs, Jr, EARL M. HARDINE. 

